Method of making fibrous products



Nov. 20, 1951 G. J. SLUITER 2,575,895

METHOD OF MAKING FIBROUS PRODUCTS Filed Sept. 22, 1949 INVENTORZ c Emu-r JmMNNES F|G.4 FIGBBY ATTORNEY Patented Nov. 20, 1951 UNITED STATES PATENT OFFICE Application September 22, 1949, Serial No. 117,247 In' the-Netherlands September 30, 1948 -Glaims. (Cl. 260-442) The invention relatesto a process for the preparation of a fibrous pap for the-manufacture of artificial products and in particular to a process for the preparation of a uniform pap,

- starch) cellulose derivati-ve agglutinants such as tylose (methyl cellulose), gums and resins (such as gum tragacanth) included, aswell as ofanimal origin such as the meat-, fishand bone-glues substantially consisting of fibrous mater-ial, glue and the caseinand albumin-glues, and also of and rubber'latex. synthetic origin.

5 It is known that in-openingin water fibre In selecting the glue, it has to be considered aggregates such as chemically'free cellulose in that it is undesirable in several cases that the amore-orless'pure condition in the form of pulp products give out unpleasant smells. In particor wadding of-w0od; straw -'or the like, it is very ular with proteinous glue thesemay assert themdiificult to disengage the fibres from each other. selves in an awkward degree in exposing to the In rubbing a sample between the fingers the air.

" fibres stick together in the form of barley-cornihe minimum amount-of glue that is neceslikeclods. Th-is 'phenomenon interferes indifsary is determined by the requirement that a ferent' processes in which fibres'are worked up sufficient disengagement of the fibres and a uniinto uniform artificial masses. form distribution throughout the glue dispersion The present-invention has in view to meet this is obtained.

"objection -in-makingfirstlya uniform fibrous The invention 'will' be more fully understood suspension-by thatdryfibre' aggregates are added from the following detailed description in conto, mixedwith and exposed to the action of a junction with the accompanying drawings in uniform aqueous glue-dispersion and-thereupon which:

- thoroughly beaten through this glue dispersion Figs. 1 to 8 are fragmentary perspective views before the whole is worked'up-with aids and apof coverings made in accordance with the pliances into a uniform fibrous pap from which invention. the artificial products are to be manufactured. Without restricting theinvention to the recipe It is found that by application of this process following hereafter, an example for the preparaa 'much' better uniformdistribution-of the fibres tion of a uniform suspension of fibres in aqueous through the pap; from which the artificial prodglue is now given. Naturally the process for the ucts' are to be manufactured,is'obtained-and preparation of the glue dispersion used therein that'in this'way theconvertibilitybf the pap 3() depends on thecharacter of the glue and thereand the properties of the artificialproductstherefore is liable to alterations.

from are'improved to an unprecedented extent. Emmple 1 Preferably the fibrous suspension is left to itself for a period of the order of several hours, 525 parts by weight of glue, for example the "for'example duringa day,' before the fibres are Swedish naturalstarch product known under "beaten through the glue dispersion. the registered trade-mark fAlkasit, stirred In the process according to the invention 1:10 with water. The mass .is thoroughly mixed chemically free cellulose in a more or less pure and then preferably left forswelling durin some condition in the form of pulpor 'wadding. of time, for example la-1 hour. The thus obtained -wood, straw, or 'thelike canadvantageously. be 40 thick uniform paste is'diluted with water, 1:1. usedas a fibre aggregate. Into the ready glue dispersion fibre aggregate It is known per'se to work-up fibres together is introduced in one or more charges, for example *with glue and latex and if desired-fillers. Sin 5 pa s by weight'of Cellulose. Wedding,

" the known process the glue was -not'used,- howmade from chemical p p used in the manuever, for'prior preparation of a uniform fibrous facture of pap thereupon mixed With the u glue suspension in the above indicated way. Also dispersion and left standing for some time, for

the glue was added irrespectively of whether example during a day. Thereupon the fibres fibrous fillers were used or not, and naturally are thoroughly beaten u h the lu disperthe applied percentage of glue was not specifically sion until a uniformpap is obtained.

adapted to the applied amount of-fibrous ma- The thus obtained fibrous suspensioncan-adterial. vantageously be applied for mixing with rubber In the process according to theinvention the latex. Whereas it is extremely diifieult to mix glue can be of vegetable origin; such as'vegetable dry fibres such as cellulose with latexwithout 'protein glue,starch products fromigluten ('zeine), coagulation unless the latex isstabilized very starch derivative agglutinants (dextrin; swelled lthoroughly fibrous suspensions obtained accordfibres, glue, aids and appliances.

ing to the process of the invention are very uniform and mixable without coagulation with normally preserved, inhibited and stabilized latex.

Preferably cream latex, that is latex which is concentrated to about 60 percent by weight of solids, is used therein. It is true that the so called revertex, which is concentrated to amply '70 percent by weight of solids, may also be used, but usually it is too expensive. Latices containing more water, such as latex with about 38-40 percent by weight of solids will give a pap that is too thin for some objects if the ratio of solids in the pap is wanted to bemaintained. Natural rubber latex as well as synthetic latices can be used. The latices may contain self .vulcanizing agents and accelerators.

As a greater ratio of rubber is incorporated in i the pap, the products obtained from the latter will be of better quality; the higher latex con-l tents and the higher concentrations of fibres and aids and appliances coupled therewith simultaneously increase the cost price however.

To illustrate this application of the fibrous suspensions the following recipe is given:

Example 1 125 parts by weight of cream latex containing stabilizer, anti-oxidant and preservator is added under stirring to the pap obtained accordingly to the preceding Example 1.

By making use of the above mentioned principle it is possible, if desired under addition ofaids and appliances, to prepare a pap which, according to the composition, can be worked up by brushing up, bulking, casting, spraying and the A plurality of coverings made in accordance;

with the invention are shown by Way of example in the drawings. Fig. 1 shows a covering consisting of a layer I made from the final pap only and thus substantially consisting of rubber,

a covering consisting of a layer I superposed on a supporting underlayer 2. Fig. 3 shows a covering consisting of two layers I with an intermediate supporting layer 3. Fig. 4 illustrates the removal of the underlayer 2 from the layer I of the covering shown in Fig. 2. Figs. 5 to 8 correspond to Figs. 1 to 4 respectively and show the coverings thereof provided with a relief 4.

Fillers may be added to increase the hardness of the products manufactured with the pap. Very suitable for this purpose is, for example chalk, of which according to the desired increase of the hardness, more or less is added (for example 125-300 parts by weight), mixed with water in a ratio that is dependent i. e. on the filler quality. Thus it makes a difference e. g. whether the chalk is medicinal or twice washed. The ratio lies mostly at about 1:1. The most uniformdistribution is obtained by adding these fillers to the glue dispersion, i. e. prior to the addition of the fibre mass.

Still harder products can be obtained by incorporation of gyps (plaster), cement or similar fast-hardening materials, for example 100 parts by weight in 50 parts of water. These ingredients Fig. 2 shows 'weight in 60-70 parts of water.

4 may be added to the glue dispersion or to one of the subsequent semimanufactured products or to the final product.

In order to increase the cohesion capacity on surfaces (walls and the like), to increase the mechanical strength and to decrease the stickiness of the products to be manufactured, water glass is generally added, for example 30 parts by This may be done during the beating of the fibres through the glue dispersion, or the water glass may be added later on, even simultaneously with the addition of the latex.

Pigments maybe added to any of the components of the pap," or to the semi-manufactured or final product. Preferably latex dye is used for this purpose as only a small quantity thereof is necessary thanks to its strong colouring power.

In some cases application of latex with self vulcanizers and accelerators is of special advantage, for example if covering material for furniture has to be manufactured or if the pap is worked together with an under or intermediate layer of fabric.

Though the products obtained from the pap are poorly inflammable, it can be useful in special cases, such as for wall coverings in ships, theatres and the like to decrease the inflammability by addition of powdered asbestos, alum and the like, preferably to the fibrous material prior to the addition of the latter to the glue dispersion.

Mention has already been made of the fact that the pap can be made as a sprayable pap. For that purpose it is necessary that the water ratio is higher thanfor the spreadable pap. A satisfactorily sprayable product can be obtained for example by addition of a suitable amount of Water to the spreadable pap or by addition of this extra water during one or more stepsof the preparation of the pap.

Another suitable sprayable pap can be obtained according to the following example.

Example 1 To parts by weight of a solution of caseinate glue and borax in water in a ratio by weight of 101%:80 a preservator is admixed. Half of this bath is added to 167 parts by weight of cream latex together with vulcanisation dispersion. The remaining half is added to the pap obtained according to Example 1, during the preparation of which 200 parts by weight of chalk in 400 parts of water and 30 parts by weight of water glass in 70 parts of water are added. Thereupon the latex liquid and the pap are mixed under stirring.

In preparing a sprayable pap it is recommended to add a frother such as a special soap. The spraying can be carried out i. c. with the aid of a special motar gun with compressor.

A particular property of very great importance for products that are manufactured with latex, is the porosity. By application of the fibrous suspension obtained by the process according to the invention it appears that a rubber cellulose product can be manufactured that is waterproof and nevertheless gas-permeable so that no inconvenience is met with by condensation deposits on the surfaces of these products.

I claim:

1. A process for preparing a fibrous composition containing cellulose fibres, glue and a rubber in aqueous dispersed form which comprises adding 70-80 parts, by weightof loosely cohering fibrous cellulose flock to a uniform aqueous dispersion of 5-25 parts by weight of glue, intimately mixing said fibrous cellulose flock with said glue dispersion, allowing said mixture of cellulose flock and glue dispersion to stand for a period of several hours, thereafter beating the fiber glue dispersion to efiect uniform suspension of loose fibers in the glue dispersion, and mixing said suspension with 75-100 parts by weight of rubber solids in latex form, whereby to form a uniform composition adapted to be shaped and dried to form flexible articles.

2. A process as defined in claim 1, wherein an aqueous suspension of 125-300 parts by weight of chalk is added to the glue dispersion prior to the addition of the cellulose flock.

3. A process as defined in claim 1, wherein 20-40 parts by weight of water glass are added to the suspension of loose cellulose fibers in the 5. A flexible product obtained by removing water from a uniform fibrous composition comprising, in intimate admixture, 75-100 parts of a rubber in the form of a latex and an aqueous glue dispersion containing 5-25 parts by weight of glue, and 70-80 parts by weight of loose cellulose fibers suspended therein, said loose cellulose fibers being derived from cellulose flock.

GERRIT JOHANNES SLUITER.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date Re. 21,575 Tator Sept. 17, 1940 1,765,015 Hopkinson June 17, 1930 1,883,106 Thoma Oct. 18, 1932 2,127,298 Isaacs Aug. 16, 1938 2,215,553 Johnson Sept. 24, 1940 2,278,943 Oesterreich Apr. 7, 1942 2,333,265 McIntosh et al Nov. 2, 1943 2,474,801 Owen June 28, 1949 

1. A PROCESS FOR PREPARING A FIBROUS COMPOSITION CONTAINING CELLULOSE FIBRES, GLUE AND A RUBBER IN AQUEOUS DISPERSED FORM WHICH COMPRISES ADDING 70-80 PARTS BY WEIGHT OF LOOSELY COHERING FIBROUS CELLULOSE FLOCK TO A UNIFORM AQUEOUS DISPERSION OF 5-25 PARTS BY WEIGHT OF GLUE, INTIMATELY MIXING SAID FIBROUS CELLULOSE FLOCK WITH SAID GLUE DISPERSION, ALLOWING SAID MIXTURE OF CELLULOSE FLOCK AND GLUE DISPERSION TO STAND FOR A PERIOD OF SEVERAL HOURS, THEREAFTER BEATING THE FIBER GLUE DISPERSION TO EFFECT UNIFORM SUSPENSION OF LOOSE FIBERS IN THE GLUE-DISPERSION, AND MIXING SAID SUSPENSION WITH 75-100 PARTS BY WEIGHT OF RUBBER SOLIDS IN LATEX FORM, WHEREBY TO FORM A UNIFORM COMPOSITION ADAPTED TO BE SHAPED AND DRIED TO FORM FLEXIBLE ARTICLES. 